i was wondering if there are any bugs with the D2. on other forums that i have read, ppl say that they have bricked there D2 and that the power button were falling off.

All players have bugs, personally I don't have a d2, but the i7 and I've found no bugs with latest firmware update other than aa on ogg or flac, which I don't use. That said, from my experience cowon has great build quality, if someone was complaining, they probably abused their player.

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When making a playlist, is it easy to make an "on-the-go" playlist.

Yes, DPL (dynamic playlist) and you don't have to go to various folders, can be done from the dpl folder.

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how can you put files onto the expansion card?

drag & drop, no special software needed.

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does the D2 support album artwork? Does the D2 have the ability to shuffle AND repeat while playing music, and does the shuffle work well?

Yes, Yes, Yes and Yes

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also i would like ask if the support from Cowon is good. i live in the States and i dont want to be stuck with a screwed up player

You can get it from jetmall.net, ebay, and B&H photo. It supports SDHC or just normal SD cards. It comes with a dictionary and a calculator, but it can also handle some flash apps if you can find them, such as games.

You can get it from jetmall.net, ebay, and B&H photo. It supports SDHC or just normal SD cards. It comes with a dictionary and a calculator, but it can also handle some flash apps if you can find them, such as games.

Well regarding those stores...I'm refering to the ones that are authorized retailers..so eBay may not count. Some companies don't support the warranty if its not from authorized retailers.
Know anything about 32GB SD card support?